Method and apparatus for handling continuous filamentary material



Nov. 3, 1964 H. J. HoAG, JR., ETAL 3,154,836

METHOD AND APPARATUS FDR HANDLING coNTINuous FILAMENTARY MATERIAL FiledOct. 3l. 1960 2 Sheets-Sheet 1 HAPPY J. H046, Ef

JOHN A//E/D/NGER INVENTURS t Arrow/5v5 Nov. 3, 1964 H, J. HoAG, JR.,ETAL 3,154,836

METHOD AND APPARATUS FOR HANDLING CONTINUOUS FILAMENTARY MATERIAL FiledOct. 31, 1960 2 Sheets-Sheet 2 HARRY J H046, JR. 8:

./oH/v A. MHD/N651:J

INVENToRs A TTO/PA/Eys United States Patent O Harry J. L

Alto, assignors to @wens-Corning Fiberglas poration, a corporation ofBelaware Filed Get. 31, i959, Ser. No. 615,093 il Claims. {f-C. Erl- 54)'l`his invention relates to handling continuous lilamentary material instrand, yarn, or like form. More particularly, the invention relates toa method and apparatus for the supervised advancement of continuousamentary material in the direction of its length from a supply thereofto a station where the material is further processed, or is incorporatedin a product being formed.

The term continuous filamentary material as used throughout thisspecification and in the appended claims is intended to includeindividual fibers, multi-filament strands, slivers, rovings, and othercontinuous llexible textile Lorms.

in processes wherein continuous lamentary material is continuouslywithdrawn from a supply and serially advanced by the application of atractive force thereto to a sta-ion for further processing, a variety ofproblems are encountered that are detrimental to the normal course ofthe operation, and which frequently cause serious defects in the productbeing formed from the ilarnentary material. For example, one or" themaior problems is that of a hang-up or anchoring of the iilamentarymaterial, either within the supply or along the path of its advancement.Such occurrences generally result in a complete stoppage in theadvancement of the lamentary material, or in a reduction in the rate ofadvancement of the ilamentary material below the rate necessary for thesuccessful operation of the process consuming it.

Other serious problems, often attributable to a hangup, are breakage ofthe iiiamentary material within the supply, and disruption of thematerial from the pattern in which it has been incorporated in theproduct being formed. in this connection, breaking of the llamentarymaterial within the supply results in a consideraele loss of time inlocating the broken end to restart the advancement process.

Another problem of some magnitude is that of snarls or projectingentanglements occurring along the length of the fllamentary materialwldch may cause a hangup, or a defect in the product being formed.

It i therefore, the general obiect of this invention to provide a novelmethod and apparatus for the supervised advancement of continuousiilamentary material from a supply in a manner obviating theaforementioned problems.

More specifically, it is an object of this invention to provide a methodand means for the continuous supervised advancement of iilamentarymaterial from a supply thereof, a manner wherein there is an immediateseverence of the ilamentary material in the event of a stoppage or of areduction in the rate of advancement of the filamentary material below arate that has been predeterminedly established for the successfuloperation of a process.

A further object of this invention is to provide a method and apparatuswhich will provide a free end of the larnentary material available forimmediate restitution of the processing operation when severing of theiilarnentary erial has become necessary.

A still further obiect of this invention is to `provide a method andapparatus which will prevent breaks in nce the iilamentary material fromoccurring in the convolutions of the supply.

A still further object of this invention is to provide method and meansfor sensing the surface of advancing ilamentary material for snarls andentanglements being c rried along thereon and preventing the advancemento such snarled and entangled material in the event of such occurrences.

Another object of this invention resides in the provision of a methodand apparatus for the supervised delivery of continuous filamentarymaterial for incorporation in a mat type product being continuouslyformed, in a manner whereby disruption or displacement of theiilamentary material from the pattern in which it is incorporated in themat is substantially prevented.

For this accomplishment of the aforegoing objects, in accordance withthis invention the filamentary material is continuously withdrawn from asupply and serially advanced lengthwise along a predetermined path anddelivered to a station for further processing by the application of atractive force thereto. In successive zones along this path, in advanceof the point of application of the tractive'force, the surface ofcontinuous iilamentary material is irst sensed for snarls orentanglements occurrin T thereon, and then enveloped with aconcentration of heat at a temperature sufficient to sever thelilarnentary material in the event of a stoppage or reduction in therate of delivery of the material below a predetermined rate.

The aforegoing objects of the invention and other objects and advantageswhich hereinafter appear may be fully understood from a study of thefollowing detailed description taken in connection with theaccompartying drawing which is illustrative of a preferred embodiment ofthe invention, it being understood, however, that the invention is notrestricted to a strict conformity with the showing in the drawing butmay be changed and modiiied as long as the changes make no materialdeparture from the salient features of the invention as expressed in theappended claims.

In the drawings:

FIGURE l is a side-elevational View in perspective, partially brokenaway and partially in section, illustrating the invention in conjunctionwith the formation of a continuous strand reinforced mat;

FlGURE 2 is an enlarged view, in perspective, with parts broken away ofportions of the apparatus shown in FlGURl-E l, and showing with greaterparticularity the supervised advancement of a length of continuousiilarnentary material in accordance with the practice of the presentinvention; and

FGURE 3 is an enlarged plan View of a portion of the mechanism forsensing the surface of the lamentary material and guiding it in relationto the severence means.

To provide a better understanding of the invention, is ereinafter shownand described in conjunction with a process for the formation of afibrous mat reinforced with continuous r'ilarnentary material. Processesof this nature are not amenable to a start-stop operation. This is aparticular disadvantage when one or more individual lengths of thecontinuous iilamentary material suffer a stoppage or severe reduction inthe rate of its delivery. Such conditions if not immediately relievedimpart severe defects in the mat being formed. A" will be apparent inthe following description the practice of this invention obviates suchdhiiculties. Corresponding advantages are achieved in the fabrication ofother textile products incorporating continuous filamentary material,

ln the embodiment of the invention illustrated in FG- Y such processesserious diiiiculties, such as the ale/gaas URE lV molten glass 1li iscontinuously issued in the form of molten streams 11 from Va pluralityof outlets 12 provided in the bottom of a feeder 13. The streams 11 areengaged by high velocity gaseous blasts, issuing from a blower 14. Theblasts attenuate the molten streams 1l into a multiplicity of linefibers 15 which pass downwardly into a collection hood 16.

Centrally disposed Within the hood 16 is a shield or divider 17 oftentlike configuration with its apex located in the upper portion of thehood 16 beneath the hood opening. The divider 17 serves to separate thedown- Wardly moving discontinuous bers into two groups and provides ashielded zone above a foraminous endless conveyor 18 traveling beneaththe hood 16 for the incorporation of continuous fllamentary material 22with the discontinuous iibers 15 being collected thereon.

As the conveyor 18 travels beneath the hood 16 the first group of thediscontinuous fibers 15 are interfeltingly layered thereon in a randomdistribution. A plurality of lengths of continuous lamentary materialare then randomly distributed thereover in the zone beneath the hooddivider 17. As this fibrous mass is moved forwardly by the conveyor intothe hood zone beyond the divider 17 the second group of discontinuousfibers is randomly applied thereon.

Deposition of the `discontinuous fibers 15 and the continuous lamentarymaterial on the conveyor 1S is facilitated by suction or subatmosphericpressure produced in chamber 19 disposed beneath thevupper section ofthe conveyor. Duct 2l) connects the chamber with suitable negativepressure producing mechanism (not shown).

Upon passage out of the hood area the reinforced mat 21 is continuouslyadvanced to suitable apparatus for further processing and packaging.

Reinforced mats of this type produced in the aforesaid manner are Wellknown in the art, and therefore do not constitute per se a part of thisinvention. However', in hang-ups, stoppages, and snarls previouslymentioned, have been experienced in the delivery of the continuouslamentary material to the zone of its application to the mat beingformed. These diliiculties have made the supervised advancement of thecontinuous iiiamentary material in accordanceV with the practice of thisinvention invaluable.

The continuous flamentary materialto be incorporated as a reinforcementin the mat 21 may be, for example,

' a plurality of continuous glass filaments in the form of a strand 22.Y

The number of strands utilized and the pattern of their assemblage inthe mat 21 may be varied to provide different strength characteristics,however, Vto avoid serious defects in the end product each strand 22must be supervisedly delivered. To this end, there is provided a supportmember 25 located laterally adjacent chamber 19 and exteriorly of thehood 16. Aliixed thereto are a plurality Vof package holders 24, eachadapted to hold a supply or package 23 of continuous strand 22.

Above each package 23 is a strand advancing and delivery tube 26provided with a tubular fitting 27 for the introduction of pressurizedair into the bore of the tube. The inlet opening of each tube 2o ispositioned abovethe respective package 23 from which it is to withdraw astrand 22 and deliver it to the mat. Each tube 26 extends through lthesidewall of the hood 16 into the shielded zone above the conveyor 18provided by the divider 17. The outlet opening of each tube 26 isdirected toward the conveyor 18 to provide an area coverage of aportion-of` the surface of the mat layer being advanced thereon. Aplurality of such tubes extend as a bankV into the zone under thedivider 17, the outlet opening of each tube 26 being positioned inspaced rela- Ytion With the outlet openings of the other tubes to assurefullcoverage of strands across the width of the conveyor 18.

Suitably supported adjacent and below the inlet opening of each tube 26and in the path of advancement of the strand 22 from its package 23,there is provided a strand monitor 29 to lirst sense the advancingstrand for snarls or entanglements projecting therefrom, and secondly tocontinuously apply a concentration of heat to the strand at atemperature sufiicient to sever the strand in the event of a stoppage orreduction in the rate of its advancement below a predetermined rate.

As is more clearly seen in FIGURES 2 and 3, in this embodiment, thestrand monitor 29 includes an open llame burner 31, and a strand sensingand guide mechanism 32.

The sensing and guide mechanism 32 is a at plate having a generallyhorizontal orientation, with its top surface at one end being aihxed tothe bottom surface of the block of the burner 31, and having divergingarms 33 and 34 projecting from the side of the plate near the other endthereof. The inner side edges of the arms 33 and 34V are joined by anintermediate arced portion 35 above which a spiral guide coil 37 islocated in centered relation. The coil 37 is secured to the plate by arm36 extending from the coil being fastened to the plate by a retainingclip 38 and screw 39. The coil 37 is centered over the arced portion 35of the plate. The coil 37 is spiraled vertically with its first turn oflargest dimension being smaller than the arced portion 35 of the plateby an amount suiiicient to allow free circular entry of the strand intothe center opening of the spiral coil 37. The coil 37 is spiraled in thedirection of lateral movement imparted to the strand 22 in unwinding itfrom its package 23. The center opening of the spiral coil 37 is madesufficiently large to allow free axial movement of unsnarled portions ofa strand therethrough, but is sufficiently small so that the coil 37will restrict and halt the passage of large snarled and entangledportions of a strand.

ln the burner 3i, a hollow, diverging Wall flame tunnel 4@ is suppliedwith a metered mixture of gas and air through a pipe 36 adapted to beconnected with a suitable supply. The circular face l1 of the tunnel lllcontains a slot .2 of dimension slightly greater than that of the strand22. The slot 42 is aligned with the center opening in the coil 37therebelow. The gas-air mixture ignites within the tunnel lll andprojects as an open ame 43 beyond the face 41 to completely envelop theVstrand 22.

ln operation, the end of a strand 22 is Withdrawn from its respectivesupply 23 and threaded through the inlet opening of its associated tube26. Air from a suitable supply is continuously admitted under pressurethrough the fitting 27 into the bore of the tube 26. The air creates azone of reduced pressure at the inlet opening of the tube 26 therebyfacilitating threading. The advancing air surrounds the strand applyingan impositive force thereto. This force acts to continuously Withdrawthe strand 22 from its package 23, advance it through the tube 26, andeject it through the tube outlet over the conveyor 18. By regulation ofthe supply of air the desired rate of advancement of the strand isestablished.

The strand thus delivered to the conveyor is haphazardly deposited in arandom pattern to cover a portion of the layer of discontinuous fibers.The adjacently spaced tubes each similarly deliver a strand. The spacingof the tubes is such that there is a degree of zonal overlap of thestrands on the moving conveyor 18 'from immediately adjacent tubes. Thiszonal overlapping distribution reduces the possibility of the formationof a weakened area in the mat during the short period when a strand isnot fed to a particular zone due to the severance of the strandoccasioned by a restriction on its advancement. Severance of a strand inthe manner of this invention provides a free end conveniently availablefor quickly restarting the strand delivery operation.

After the strand 22 has been threaded through the inlet opening of itsassociated ytube 26 and the tractive force for its advancement appliedthereto, the strand path in relation to the monitor 29 is established.This it finds the slot 42.

is essentially a self-threading process. As the strand 22 is withdrawnfrom its package 23 it follows a laterally circular upward path. Theopening between the projecting arms 33 and 34 of the guide mechainism 32is interceptingly located in the path of movement of the strand. Uponcontacting the interior sides of these arms, and guided thereby, thestrand passes under the impetus of its lateral movement into the pathdefined by the arced portion 35 or" the plate and the side of the spiralcoil 37, and progresses into the center opening of the coil 37. At thesame time that the lrand 22 moves into the Ycenter opening of the coil37, it also becomes engaged in the slot i2 on the lower edge or" theface il of the llame tunnel 4t) since the slot 42 is aligned with thecenter opening in the coil. At times the strand will momentarily ride onthe lower portion ot" the face 4l until in this connection, the face 4iis angularly oriented with respect to the path or" the strand 22, andthe strand generally does not contact the upper portion of the face 4l.

As the strand is advanced through Vthe coil 37 and the slot 42, anysnarls and entanglements projecting from yits surface result in itsmovement being halted or restricted by the coil 37 and/or slot d2 to adegree sufcient to eect a severance of the strand 22 by the llame 43. Insuch event the severed end in advance of the slot lprogresses throughthe delivery tube 26, and the snarled end is conveniently located forclipping and rethreadiag in its tube 25. By its engagement in the coil37 and in the slot 42, the strand 22 is guided and maintained in itspath through the open llame 43.

The continuous application of the flame 43 to the strand has been foundto be of value in discharging static charges from strand of a type, suchas glass, which tend to accumulate such charges during their handling.Such discharge is eEected by the ionizing character of the flame.

In normal operation the advancement or the continuous strand 22 from itssupply package 23 to the Zone of its incorporation with the layer ordiscontinuous t'ibers on the moving conveyor '18 is continuous, andsevering of the strand by lthe ame 43 only occurs when normaladvancement is interrupted, for example, by a hang-up or anchoringthereof.

In the event of such interruption or stoppage, the strand 22 were notmonitored, severe defects would be imparted to the mat since a pullwould be exerted on that part of the strand already incorporated in thediscontinuous libers caried along on the moving conveyor. Such pullseffect a dislodgernent of the strand from the pattern in which it hasbeen incorporated in the mat, and also disrupt or dislodge the adjacentdiscontinuous iibers, forming a blemish or strength defect in the mat.In the production of thin mats such pulls generally result in adislodgement of strand and liber sudicient to form a hole or vacant areain the mat. Further, the

Y dislodged strand and ber fold back on themselves, creating an area of1'ricreased thickness adjacent the vacant area, thus portions of the matformed have to be scrapped and as such mats are often formed in 56 and72 widths considerable material is wasted.

In view of the severity of these problems caused by such a pull beingexerted on the strand, the necessity for immediate remedial action isapparent. As previously refered Ito, this action is provided by thecontinuous application of the concentration of heat to the strand beingadvanced at a temperature suicient to sever the strand when it is movedat a rate less than a predetermined rate.

The temperature of the severing zone is adjusted in accordance with therate at which the strand is to be advanced, the length of the heatedzone, and the character and thickness of the strand. By way of example,exible glass strands of dimensions in the range available for commercialuse moving at a rate of 2060 per minute can be successfully monitored bya 1" diameter llame at a temperature in the range of 2800" to 3000 F.l'iurther, by way of example, the burner can be made to en'"ect asevermce of such a strand when it moves at a rate slower than 250 perminute, but it will be recognized in view of the present descriptionthat the predetermined rate below which severance occurs can be modifiedby adjustment of the above-mentioned interrelated variables forestablishment of the required concentration of heat.

The strand monitor of the inventionY affords many advantages in thatthere are no moving parts, it is .compact, readily adjustable, andpractically maintenance free. Further, it prevents breakages due toanchoring of the strand in the package, as the strand will be severedbefore sufcient force is applied thereto to break it in the package.

it is readily apparent that the supervised advancement oi' continuouslamentary material in accordance with the method and apparatus of thisinvention may be utilized in processes other than that described. Forexample, the method and apparatus of this invention may be employed toform a continuous strand mat by directing a plurality of tubes eachfeeding an individual strand to a moving collection surface forassemblage of a mat completely made up of continuous strand material.

Various other mod ications may be made in the invention within thespirit and scope of the appended claims to meet diverse requirements.

We claim:

l. A method for the supervised advancement of a continuous length ofiilamentary material comprising linearly advancing a continuous lengthof lamentary material from a supply along a given path, concentratingheat in a short zone along the length of the path of advancement of saidmaterial, and maintaining the concentration of heat at a temperaturesutlicient to sharply sever the material within a short distance ofmovement when the material is advanced at a rate less than apredetermined rate.

2. A method for the supervised advancement of a continuous length ofilamentary material comprising continually withdrawing said materialfrom a supply and feeding it in the direction of its length along agiven path by the application of a tractive force thereto, andenveloping said material between the Zone of application of the tractiveforce and the supply with a narrow band of open flame at a temperaturesui'icient to sever said ilamentary material when the rate of feed ofsaid material is less than a predetermined rate.

3. A method for the supervised advancement of a continuous length ofiilamentary material from a supply thereof comprising continuallywithdrawing said material from a supply and advancing it lengthwisealong a given path by the application of a pneumatic force thereto, andenveloping said iilamentary material .in an open llame of relativelysmall dimension in a Zone between the region of application or" thetractive force and the supply, said open llame being at a temperaturesufficient to sever the strand when the rate of advancement of thelilamentary material is less than a predetermined rate.

4. A method for the supervised advancement of a continuous length orrilamentary material from a supply comprising continually withdrawingsaid material from a supply and advancing it in the direction of itslength along a given path by the application of a tractive forcethereto, engaging said material between the zone or" application of thetractive force and the supply with a concentration o heat in a shortZone along the path of advancement oi' the lilamentary material at atemperature suicient to sever said lamentary material when the rate ofadvancement of said material is less than a predetermined rate, andpassing said iilamentary material through a surface sensing system inadvance of its engagement by said concentration oi heat, said systemoperable to stop the area-,ese

advancement of the lamentary material in the event of snarls andentanglements being carried along in projecting Yrelation with thesurface of said filamentary material.

5. A method for the supervised advancement of a continuous length ofiilamentary material comprising continually withdrawing said Vmaterialfrom a supply and advancing it in the direction of its length along agiven path by the application of a tractive force thereto, envelopingsaid material in a zone between the region of application of thetractive force and the supply with an open ame at a temperaturesutiicient to sever the iilamentary material when the rate ofadvancement of the material is less than a predetermined rate, sensingthe surface of the lamentary material in advance of its introductioninto the open flame to detect irregularities in dimensional Ylinearitysuch as snarls and entanglements, and restraining the advancement ofsaid lamentary material upon detection of such an irregularity whereuponsaid filamentary material is severed by said open flame.

6. A method for the supervised advancement of a continuous lengthoffilamentary material from a supply comprising continually withdrawingsaid lilamentary material from a supply and advancing it in thedirection of its length along a given path by the application of apneumatic force in impositive engaging advancing relation therewith,enveloping said material-between the zone of application of said forceand said supply with an open iame in a short zone along the path ofadvancement of the tilamentary material at a temperature sutlcient tosever the iilamentary material when the rate of advancement ofk saidmaterial is less than a predetermined rate, sensing the surface of thetilamentary material in advance of its introduction into the open flameto detect irregularities in dimensional linearity such as snarls andentanglements, and restraining the advancement of said lamentarymaterial upon detection of such an irregularity whereupon said lamentarymaterial is severed by said llame. v

7; In a process for forming on a moving collection surface a fibrous matincorporating continuous length lilamentary material, the steps ofcontinually withdrawing said lamentary material from a supplyandffeeding it in a direction of its length along a given path by theapplication of a vtractive force thereto in a zone spaced from saidsupply and adjacent a moving collection surface, serially depositingsaid material on said collection surface while preserving the continuitythereof with said supply, and enveloping said iilamentary material in azone of relatively short length adjacent the Zone of application of saidtractive force with a concentration of heat at a temperature suicient tosever said iilarnentary material when the rate of feed of said materialis less than a predetermined rate.

8. In a process for forming a fibrous mat incorporating continuouslength tilamentary material, the steps of continually withdrawing aplurality of lengths of filamentary material each from a preformedsupply thereof, continually -lineraly advancing each of said lengths byapplying a pneumatic force thereto in a zone spaced from said supply andadjacent a foraminous moving collection surface, serially depositingeach of said lengths on said surface while preserving the continuity ofeach of said lengths between said surface and its supply, and envelopingeach of said lengths of said iilamentary material in a zone'adjacent thezone of application of the pneumatic force with an open flame at atemperature suiiicient to sever said lengths when the rate of feed ofsaid lengths is less than apredetermined rate.

9. In a process for forming on a moving collection surface a iibrous matincorporating continuous length lamentary material, the steps ofcontinually withdrawing and linearly advancing a plurality of continuouslengths of lamentary material from the respective supplies thereof byapplying an impositive force in the form of a gaseous blast insurrounding relation with each of said lengths, conveying each of saidlengths by means of said blast to a foraminous moving collectionsurface, establishing a negative pressure zone under said collectionsurface, depositing said lengths on said surface while preserving thecontinuity of said lengths with their respective supplies, envelopingeach of said lengths in a given zone between the zone of application ofsaid blast and its respective supply with an open flame individual tosuch length and at a temperature sufficient to 'sever such length whenit is advanced at a rate less than a predetermined rate, sensing thesurface of each of said lengths of lamentary material in advance of itsintroduction into the zone of flame envelopment to ydetectirregularities in dimensional linearity such as snarls andentanglements, and restraining the advancement of any of said lengthsupon the detection of such irregularity on its surface whereupon suchlength is severed by said concentration of heat.

10. Apparatus for the supervised advancement of a continuous length ofiilamentary material comprising a supply of said lamentary material,tractive means spaced from said supply for continuously withdrawing andadvancing said material therefrom, and open flame producing meanslocated in advance of said tractive means and positioned to continuouslyapply a concentration of heat across a short-length of the path oftravel of said amentary material at a temperature sucient to sever saidmaterial when it is advanced at a rate less than a predetermined rate.

11. Apparatus for the supervised advancement of a vcontinuous length ofiilamentary material comprising a supply of said iilamentary material,pneumatic means spaced from said supply for continuously withdrawing andadvancing said material therefrom, flame producing means located inadvance of said pneumatic means and positioned to` continuously apply aconcentration of heat to said lamentary material in a short zone alongthe path of advancement of the iilamentary material at a temperaturesuicient to sever said material when it is advanced at a rate less thana predetermined rate, and a spiral coil positioned in the path ofadvancement of said material in advance of said darne producing means torestrain the movement of said ilamentary material when snarls occurthereon.

References Cited in the file of this patent UNITED STATES PATENTS1,526,381 Mettler Feb. 17, 1925 1,669,033 Muller May 8, 1928 1,777,221Petitalot Sept. 30, 1930` 2,195,357 Carter Mar. 26, 1940 2,266,899 OwensDec. 23, 1941 2,565,500 lngham Aug. 28, 1951 Y 2,801,673 Welsh Aug. 6,1957 y 2,936,511 Wilson May 17, 1960 2,942,325 Spellman June 28, 19602,944,319 Crouzet `l'uly 12, 1960 2,958,921 Gilchrist et al Nov. 8, 19602,969,580 Wyner lan. 31, 1961 2,974,391 Speakrnan et al Mar. 14, 1961

10. APPARATUS FOR THE SUPERVISED ADVANCEMENT OF A CONTINUOUS LENGTH OF FILAMENTARY MATERIAL COMPRISING A SUPPLY OF SAID FILAMENTARY MATERIAL, TRACTIVE MEANS SPACED FROM SAID SUPPLY FOR CONTINUOUSLY WITHDRAWING AND ADVANCING SAID MATERIAL THEREFROM, AND OPEN FLAME PRODUCING MEANS LOCATED IN ADVANCE OF SAID TRACTIVE MEANS AND POSITIONED TO CONTINUOUSLY APPLY A CONCENTRATION OF HEAT 